Reinforcing material and manufacture thereof



Oct. 12, 1937. 1.. w. cRoss REINFORCING MATERIAL AND MANUFACTURE THEREOF Filed Oct. 26, 1934 3 Sheets-Sheet l I in- INVENTOR Oct. 12, 1937. w. cRoss REINFORC ING MATERIAL AND MANUFACTURE THEREOF s Sheets-Sheet I 2 Filed Oct. 26, 1934 v INVENTOR Oct. 12, 1937. w. cRoss REINFORCING MATERIAL AND MANUFACTURE THEREOF Filed Oct. 2 6, 1934 3 Sheets-Sheet 5 INVENTOR for Patented Get. 12, 1937 V PATENT OFFICE REINFORCING MATERIAL AND MANUFAC- TUBE THEREOF LeonardW. Cross, Wheeling, W. Va., assignor to TheConsolidated Expanded Metal Companies, Wheeling, W. Va., a corporation of West Virginia Application October 26, 1934, Serial No. 750,075

18 Claims.

This invention relates broadly to reinforcing material and the manufacture thereof, and more particularly to material comprising metal strands adapted for various structural uses, such as for reinforcing in reinforced concrete constructions. It further relates to reinforced constructions utilizing a stranded metal reinforcing material, and, more particularly, a road or like construction. The invention still further relates to a method of making expanded metal and to a machine for this purpose.

Although in certain respects the invention is not so limited, it relates particularly to the manufacture and use of expanded metal. The invention will be described with reference to the manufacture and use of expanded metal in a reinforced construction, and more specifically in a road construction. Reinforced road constructions such, for example, as reinforced concrete roads, have been, known for many years; Ordinarily steel rods or Woven steel fabricis used' as the reinforcing material. It is desirable to prefabricate so far as possible the reinforcing material to be .used in a road construction so as to reduce to thegreatest possible extent the work which has to be done in setting the reinforcing in place in the field; and it is also desirable to have thereinforcement adjacent the edges of the road, when the road comprises a single slab extending the full width of the road, or adjacent the edges of the respective slabs, when the road comprises a plurality of slabs disposed side by side, heavier than that adjacent the center of the road or of each slab, as the case :may be.

to denote either an entire roadmade up of a single slab or a component of a road made up of a plurality of slabs.

. This result has been accomplished inthe past vby adding extra reinforcing material adjacent the edges of the slabs, as by employing more layers or strands of reinforcing materialadjacent the edges than adjacent the central portions of the slabs, by using additional reinforceand requires great care in positioning and connecting the severallayersor portions of reinforcing material adjacent the edges of the slabs to properly distribute and carry the load, or it requires the fabrication of composite reinforcing memberspr. mats, which is undesirable both The word slab is used hereinafter from the standpoint of cost and from the structural standpoint.

I provide an integral piece of prefabricated structural material having a portion of heavier construction than another portion which is ideally suited for use in reinforced constructions such as roads and which obviates the necessity of handling a large number of pieces of material, avoids the uncertainty incident to setting in place a relatively great number of layers of reinforcing material or reinforcing members adjacent the edges of the slabs, and obviates the disadvantages incident to the fabrication of composite reinforcing members or mats.

I form an integral piece of expanded metal having a portion of heavier construction than another portion, such piece being characterized by relatively great strength in at least portions thereof due to cold working. In my United States Patent No. 1,691,227 I have disclosed and claimed metal lath made on a deploying type expanded metal machine having a heavier and a lighter portion. This material would not, however, serve my present purposes. Expanded metal formed on a deploying machine has staggered slits formed in the blank initially, after which the slitted' material is simply deployed or spread apart. Aside from the fact that the deploying method is only suitable for relatively light material, the material thus formed has relatively less strength than the material herein described and claimed.

I form expanded metal on a guillotine type expandedmetal machine and I vary the action of the machine so as to produce in an integral piece of the finished material a portion of heavier construction than another portion. This material is preferably of large size and may have diamonds a foot or more in length so that so far as'its size is concerned it is ideally suited for reinforcing in roads and like constructions of considerable size. Another important advantage of the material thus manufactured is that it has exceptional strength. The action of the guillotine machine results in stretching or drawing of the strands as the expanded metal is being formed, this cold working resulting in greatly strengthening the metal, particularly that of the strands, and hence greatly strengthening the finished material as a whole. Unlike the action in the deploying machine, the ends of the diamonds before, during and after formation remain at all times the samedistance apart,that, is to say, due to the characteristicsof the guillotine machine the length of each diamond is dennitely fixed and does not vary at any time during the operation. This means that as the metal is expanded the strands are elongated, the elongation of each strand being from half the length of a diamond to the length of the hypotenuse of a right triangle whose base is half the length of a diamond and whose altitude is half the final width of the diamond. This elongation will ordinarily be at least in the neighborhood of 5% and often about 7 or 8%.

As the bonds, that is to say, the integral joints or connections between the strands, being of multiple dimension with respect to the strands, are relatively strong, the strengthening of the strands due to the stretching during formation on the guillotine machine results in increase in the strength of the Weakest part of the material and, consequently, in increase in the effective or ultimate strength of the material itself. The strengthening is not confined to the strands alone but extends into the bonds at the strand ends, thus strengthening the bonds also. The strands of my new material may in certain cases have greater strength per unit cross sectional area than the bonds.

Thus the material produced on the guillotine machine is greatly superior for structural purposes to material produced on a deploying machine. This advantage becomes particularly important in the case of expanded metal having a portion of an integral piece of heavier construction than another portion, as such material formed on a guillotine machine is, as above pointed out, ideally suited for certain types of structural or reinforcing work, as in concrete roads. It has not prior to my invention been possible to form on a guillotine machine an integral piece of expanded metal having a portion of heavier construction than another portion.

Although it is preferred to realize the advantages of the guillotine machine by effecting the strengthening of the material by the stretching occurring during its formation, this being one form of cold working, it is also possible to cold Work the material otherwise, as, for example, by cold rolling it after formation. Furthermore, material which has already been stretched, and therefore strengthened, during formation can be further strengthened by further cold working after formation, as by cold rolling.

I provide novel mechanism in a guillotine type expanded metal machine for the formation of expanded metal in integral pieces each having a portion of heavier construction than another portion. Such mechanism will be described as the following explanation of the invention proceeds, as will the preferred method of making my novel product. Other details, objects and advantages of the invention will become apparent as the description proceeds.

In the accompanying drawings I have shown certain present preferred embodiments of the invention, in which Figure l is a fragmentary front elevational View of a guillotine type machine for the manufacture of expanded metal having my invention as to mechanism applied thereto;

Figure 2 is a vertical transverse cross-sectional view taken on the line IIII of Figure 1;

Figure 3 is an enlarged detail view of a portion of the construction shown in Figure 2 showing the parts in different operative positions;

Figure 4 is an elevational view, partly in vertical cross-section, of the mechanism shown in Figure 3 as viewed from the left-hand side of such figure;

Figure 5 is a fragmentary View of a piece of cold worked expanded metal having a portion of relatively light construction and a portion of relatively heavy construction; and

Figure 6 is a cross-sectional perspective view of a road construction or slab showing the application of my improved product.

Referring more particularly to the drawings, and especially to the mechanism shown in Figures '1 to 4, inclusive, there are shown, purely diagrammatically, in Figures 1 and 2 portions of a; guillotine machine for the manufacture of expanded metal. The machine comprises a feed table 2 supported upon uprights 3 and having at its upper rear edge a stationary blade 4 adapted to cooperate with a movable blade 5 carried by a vertically reciprocating head 6 whose reciprocation may be caused in any preferred man-. ner as well known in the art. The blade 5 is toothed, as shown in Figure 1, whereas the blade 4 has a smooth upper surface. A flat piece of metal or blank is shown at 1 on top the table 2, such blank being adapted to be fed into the machine or toward the right viewing Figure 2. This feeding may be accomplished by hand or automatically, as well known in the art. The forward edge of the blank strikes against a series of longitudinally spaced gauges 8 each carried by a gauge arm 9, as shown in Figure 2, the respective gauges being positioned intermediate the teeth Ill of the upper blade 5, as shown in Figure 1. Each time the blank is moved forward it strikes against and is positioned by the gauges 8 and is held in position until the blade 5 descends and severs and bends or stretches downwardly the strands of the expanded metal, these strands being integrally connected by bonds, as well known in the art. After each stroke of the blade 5 the blank is advanced and shifted laterally to stagger the strands of successive rows, also as well known in the art. This lateral shifting of the blank may be effected by hand or mechanically, there being in either case means for determining the lateral position of the blank at each operation of the blade. The mechanism thus far described is well known in the art.

So long as the gauges 8 are stationarily positioned the blank will advance the same amount each time and the strands of the ultimate product will be of uniform dimensions. I provide, however, for altering very rapidly and at the will of the operator the position of the gauges 8 so that by simple manipulation of a control device the operator can bring about the formation from time to time at his discretion of strands of predetermined dimensions without stopping or slowing up the machine.

The respective gauge arms 9 are slidable to right and left in the plane of the paper, viewing Figure 2, in a support ll. Each gauge arm has an upwardly extending heel l2, such heels being connected with one another longitudinally of the machine so as to operate at all times in unison, and springs l3 interposed between the heels and the support H urge the gauge arms and, consequently, the gauges carried thereby, toward the right, viewing Figure 2, or toward the rear of the machine, at all times. The position of the gauge arms and gauges is determined by an arm l4 keyed to a stub shaft I5 journaled in the frame and having at its outer extremity a set screw l6 maintained in fixed. position by a lock nut H, the lower extremity of the set screw abutting against the rearward face of one of the heels I 2. so as to limit the rearward movement of the gaug arms under the action of thespr'ings l3. Rotation of the shaft causes like rotation of the arm l4 and, through the set screw [6, movement of the gauge arms toposition the gauges as desired.

Also keyedto the shaft I5 and extendingforwardly of the machine and through an opening iii in the head 6 is an arm [9 whose forward extremity extends out over the table 2 and has a portion adapted for operation by the operator, as, for example, by being raised by the operator's shoulder. The arm H] has a downwardly extending stop 2! formed integral therewith, which stop is adapted normally to cooperate with the upper end of a screw 22 adapted for adjustable positioning within a clamp 23 connected with a bracket 24 fastened at 24a to a stationary part of the machine. Normally the setting of the screw 22 determines the position of the arm l9 and; consequently, of the arm- I4 and the gauges 8, as the forward or left-hand portion 28 of the arm l9, Viewing Figure 2, tends to move downwardly due to gravity and the stop 2| normally rests on the upper extremity of the screw 22. Desired adjustments may be made by adjusting the screw 22.

' Journaled in the bracket 25 is a pin 25 to which is connected at one end an operating lever 25 having a handle 21, and connected with the other end of the pin 25 is-a cam 28 adapted for rotation with the pin which, in turn, is adapted to be rotated by the lever 26. Connected with the arm I9 is a bracket 29 in which is adjustably positioned a screw 30 the lower extremity of which is adapted to rest on the cam 28. Stop members 3| and 32 in the bracket 24 determine the limits of rotation of the cam 28 in the opposite directions. These stop members may be adjustable as to position or stop members of various sizes may be substituted to obtain the desired adjustment of the limits of movement of the cam 28.

i In Figure 3 the cam is shown in dotted lines in itslowermost position. At such time the stop 2| (shown in solid lines in Figure 3) rests on the top of the screw 22, which may determine one of the desired positions of the gauges 8. The screw 30 is shown in solid and dotted lines as being adjusted so that it also at such time rests on the cam 28, although this is unnecessary as the proper positioning of the gauges would be effected 'by the screw 22 cooperating with the stop 21 alone. The cam 28 is shown in chain lines in Figure 3 in its uppermost position and with its nose portion in contact with the bottom of the screw 30, as shown in chain lines, this resulting in positioning of the arm l9in the position shown in chain lines in Figure 3. When the arm is in such position the gauges 8 are moved closer to the stationary blade 4, reducing the amount of advance of the blank at each operation and consequently reducing the width of the strands.

The operation is carried out as follows: The

' cam 28 is initially positioned in either of the two positions indicated in Figure 3, as, for example, in the chain line position in which the arm I9 is raised and the gauges 8 are moved relatively close to the stationary blade 4. The machine is operter turns with the lever and resulting in lowering of the arm 59, raising of the arm [4 and movement of the gauge arms 9 slightly toward the right, viewing Figure 2, under the action of the springs 13. This positions the gauges 8 somewhat farther from the stationary blade 4, permitting relatively great advancement of the blank at each step, this resulting in the formation of relatively wide strands. After the desired number of rela- 1 tively wide strands have been formed the lever 26 may again quickly be moved to its uppermost position or to some other predetermined position, resulting in the subsequent formation of strands of other predetermined sizes or, if the finished piece is now of the desired width, it may be cut off by raising the arm l9 toits full extent, this ordinarily being done by the operator placing his shoulder under the portion 26 and hunching upwardly. This results in the gauges 8 being moved into contact with the stationary blade 4, preventing any advance of the blank between strokes of the blade 5, and as the blank is moved laterally between strokes it will at the succeeding stroke be severed completely. The gauges may then be set as desired and a new piece of expanded metal started from the same fiat blank.

It will thus be seen that integral pieces of expanded metal having portions whose strands and bonds are of desired varying predetermined dimensions may be made on a guillotine type machine and are cold worked by the bending or stretching of the material during manufacture. For a road or slab construction, for example, it may be desirable to have a piece of expanded metal having one of the lateral halves (the length of the material being considered in the direction of the length of the diamonds) of relatively light construction and the other of relatively heavy construction. A fragment of a piece of expanded metal of this character is shown in Figure 5. The strands. 33 are relatively narrow or of light construction and the strands 34 are relatively wide or of heavy construction. The strands are connected by integral bonds 35.

Considering, for example, the upper right-hand strand 3 viewing Figure 5,'the original length in the fiat blank of the material of this strand is indicated at a, this being the length of the strand before it is stretched by the blade 5. The stretching results in its elongation to the length 0, which corresponds to the length of the hypotenuse of a right triangle the length of Whose base is a and whose altitude is b which is half the ultimate width of a diamond. Thecold working thus afforded substantially increases the strength of the strands and portions of the bonds, and,'as

slab, such piece of expanded metal having portions 38 of relatively heavy construction adjacent the opposite edges of the slab and a portion 39 of relatively light construction adjacent the center of the slab. This is simply one example showing how my novel material may be applied in actual use.

While I have shown and described certain present preferred embodiments of the invention and have explained certain present preferred methods of practicing the same, it is to be distinctly understood that the same is not limited thereto but may be otherwise variously embodied and practiced within the scope of the following claims.

I claim:

1. A generally planar sheet of expanded metal having a portion of heavier construction than another portion, said piece being characterized by relatively great strength in at least portions thereof due to cold working.

2. An integral piece of expanded metal having a portion in which the strands are of greater dimension than the strands in another portion, the strands being of greater strength per unit cross-sectional area than the bonds.

3. Reinforcing material for reinforced concrete and like constructions comprising an integral generally planar sheet of expanded metal having a portion of heavier construction than another portion, said material being characterized by relatively great strength in at least portions thereof due to cold working during formation on a guillotine type machine.

4. Reinforcing material for reinforced concrete and like constructions comprising an integral generally planar sheet of cold worked ex panded metal having a portion of heavier construction than another portion, the cold working strengthening at least portions of the material whereby the same will more efficiently perform its reinforcing function.

5. Reinforcing material for reinforced concrete and like constructions comprising an integral generally planar sheet of expanded metal having a portion in which the strands are of greater dimensions than in another portion, the strands being characterized by being stretched prior to incorporation of the material in a reinforced construction.

6. A method of making expanded metal comprising forming a blank into strands having integral connecting bonds, varying the size of the strands in the same blank, and cold working the metal.

'7. A method of making .expanded metal comprising providing a blank, forming from such blank and stretching strands having integral connecting bonds, and varying the size of the strands in the same blank.

8. A method of making expanded metal com prising providing a blank, progressively simultaneously forming and bending at 'an edge of the blank strands having integral connecting bonds, and varying the size of the strands in the same blank.

9. A method of making expanded metal comprising providing a blank, advancing said blank step by step relatively to a cutter which forms and bends strands having integral connecting bonds, and varying during advance of the same blank the extent of advance at each step.

10. A machine for making expanded metal comprising a periodically effective toothed cutter, means for supporting a blank for step by step advance relatively to the cutter, means for'determining the lateral position of the blank at each operation of the cutter, gauge means for determining the extent of advance of the blank at each step, and multi-position cam 'means for selectively predetermining the position of the gauge means.

11. A machine for making expanded metal comprising a periodically effective toothed cutter, means for supporting a blank for step by step advance relatively to the cutter, means for determining the lateral position of the blank at each operation of the cutter, gauge means for determining the extent of advance of the blank at each step, and rapidly shiftable positively stopped means for determining the position of the gauge means.

12. A machine for making expanded metal comprising a periodically effective toothed cutter, means for supporting a blank for step by step advance relativelyvto the cutter, means for determining the lateral position of the blank at each operation of the cutter, gauge means for determining the extent of advance of the blank at each step, and means predeterminedly operable without stopping or slowing up the machine and between successive operations of the cutter for selectively predetcrmining the position of the gauge means.

13. An integral piece of cold drawn expanded metal having a portion thereof, including strands and bonds, of heavier construction than another such portion.

14. An integral piece of cold Worked expanded metal having a portion thereof, including strands and bonds, of heavier construction than another such portion and having its strands of greater strength per unit cross-sectional area than its bonds.

15. An integral piece of expanded metal having a portion thereof, including strands and bonds, of heavier construction than another such portion, said piece being characterized by relatively great strength due to cold Working during formation on a guillotine type expanded metal machine.

16. A generally planar sheet of expanded metal having a portion, including strands and bonds, of heavier construction than another such portion, said sheet being characterized by relatively great strength due to stretching during formation.

17. An integral sheet of expanded metal of the type produced by cold stretching of the strands, the strands composing the diamond meshes being of greater dimension adjacent the edges of the sheet than in the center portion thereof.

18. A generally planar sheet of expanded metal having a portion in which the strands and bonds are of greater dimensions than are the strands and bonds in another portion, at least some of said first mentioned strands being characterized by relatively great strength due to stretching during formation.

LEONARD W. CROSS. 

